Tunnel boring apparatus



Dec. 24, 1968 c. R. PETERSON TUNNEL BORING APPARATUS 2 Sheets-Sheet Filed Dec. 22, 1966 INVENTOR CARL R. PETERSO FIG. 4

ATTORNEY 2 Sheets-Sheet 2 C. R. PETERSON TUNNEL BORING APPARATUS N mhm Dec. 24, 1968 Filed Dec. 22, 1966 United States Patent 3,418,022 TUNNEL BORING APPARATUS Carl R. Peterson, Princeton, NJ., assignor to Ingersoll- Rand Company, New York, N.Y., a corporation of New Jersey Filed Dec. 22, 1966, Ser. No. 603,929 17 Claims. (Cl. 299-31) ABSTRACT OF THE DISCLOSURE A tunnel boring apparatus comprising a rotatable supporting frame provided along its outer periphery with skewed cutting rollers which cooperate with the frame to form a truncated cone having its minor base at the frame leading end, and inwardly of such cutting rollers provided with other skewed cutting rollers which cooperate with the frame to form a second truncated cone having its major base at the frame leading end.

This invention relates to apparatus for boring relatively large diameter holes or tunnels in the ground and more specifically to the provision of a new and improved tunnel boring apparatus which is particularly constructed and arranged for boring a tunnel through ground including large concentrations of rock.

Conventionally, various forms of apparatus have been provided for boring tunnels of several feet in diameter through the ground. This conventional tunnel boring apparatus, however, generally is dependent upon the application of large external torques for its advancement at a satisfactory penetration rate.

An object of the present invention is to provide a new and improved tunnel boring apparatus which is particularly constructed and arranged to maintain a satisfactory penetration rate throughout its operation without the necessity for large external torques.

Another object of the invention is to provide a new and improved tunnel boring apparatus which is particularly constructed and arranged to be self-advancing into the tunnel which it bores during its formation of such tunnel.

Another object is to provide a new and improved tunnel boring apparatus which is particularly constructed and arranged to be of compact construction relative to the diameter of the tunnel which it bores.

These objects, and the other objects and advantages of the invention which will be apparent from the following description taken in connection with the accompanying drawings, are obtained by the provision of an apparatus comprising a rotatable supporting frame. A first cutting means is rotatably carried by the supporting frame adjacent the outer periphery of the latter, the first cutting means cooperating with the supporting frame to form a truncated cone having its minor base adjacent the forward end of the supporting frame. A second cutting means is rotatably carried by the supporting frame inwardly of the first cutting means, the second cutting means cooperating with the supporting frame to form a cone having a base adjacent the forward end of the supporting frame. A means is connected to the first and second cutting means for rotatably driving the first and second cutting means.

Referring to the drawings:

FIG. 1 is a view in perspective of a tunnel boring apparatus constructed in accordance with one embodiment of the present invention;

FIG. 2 is an enlarged, elevational sectional view of the tunnel boring apparatus illustrated in FIG. 1;

FIG. 3 is a schematic view of one of the cutting rollers 3,418,022 Patented Dec. 24, 1968 of the tunnel boring apparatus illustrated in FIGS. 1 and 2; and

FIG. 4 is an elevational view, reduced in size, of a tunnel boring apparatus constructed in accordance with an alternative embodiment of the invention.

Referring more particularly to the drawings wherein similar reference characters designate corresponding parts throughout the several views, as illustrated in FIGS. 1 and 2, the tunnel boring apparatus comprises a supporting frame, designated generally as 10, which has a leading end 12 and a trailing end 14. The trailing end 14 of the supporting frame 10 includes a ring member 16 which circumferentially encloses a conical opening 18 and is concentrically located within an annular support or supporting member 20. The ring member 16 is rotatably journalled upon a bearing surface 22 formed on the inner circumference of the annular supporting member 20.

The annular supporting member 20 rigidly carries a triad of rigid, arm members 24 which extend outwardly from arcuately spaced locations on the outer circumference of the annular supporting member 20. The arm members 24 are all of identical construction and each carry a wheel 26 which, as illustrated in FIG. 2, is adapted for movement on a wheel track 28 mounted upon one of the walls 30 of the tunnel bored by the tunnel boring apparatus. The arm members 24, through the engagement of their respective wheels 26 with the wheel tracks 28, serve to guide the tunnel boring apparatus and prevent undesired deviations in the direction of the tunnel which it bores.

Immediately forward of the ring member 16, the supporting frame 10 is constructed from a pair of concentric, conical body members 32, 34 rigidly connected at their trailing ends to an annular plate 36 which, in turn, is rigidly connected to the ring member 16. The body members 32, 34, as shown in FIG. 2, are arranged such that their conicalness causes them to extend outwardly as they extend longitudinally from the annular plate 36 towards the leading end 12 of the supporting frame 10. The body member 34 is disposed circumferentially around the body member 32 such that an annular space 38 is formed between the body members 32, 34; and the body member 32 circumferentially encloses a conical opening 40 which is aligned with the conical opening 18 circumferentially enclosed by the ring member 16.

A ring support 42, circumferentially enclosing an opening 44 which is aligned with the conical opening 40, is rigidly carried by the leading ends of the body members 32, 34. The ring support 42, as shown in FIG. 2, includes a plurality of arcuately extending, internal cavities 46 which communicate with the annular space 38 formed between the body members 32, 34. The ring support 42 rotatably carries a plurality of rollers 48 which, during the operation of the boring apparatus, engage the walls 30 of the tunnel formed by such apparatus to assist the wheels 26 in guiding the boring apparatus.

A ring support 50, concentric with the ring support 42 and circumferentially enclosing an opening 52, is located forwardly of the ring support 42 and forms the leading end 12 of the supporting frame 10. The ring support 50 is constructed with a diameter substantially smaller than that of the ring support 42. A plurality of arcuately spaced, toothed cutting rollers 54 are positioned forwardly of the ring support 50 for cutting an annular tunnel of greater cross section than the cross-sectional width of the ring support 50. The cutting rollers 54 are connected to the leading face 51 of the ring support 50 for independent free rotation relative to the ring support 50 by roller mountings 56. Alternatively, however, suitable percussive drilling apparatus (not shown) could be substituted for the illustrated cutting rollers 54.

A plurality of supporting shafts 58 are positioned longitudinally between the ring supports 42, 50 and rotatably journalled adjacent their opposing ends in bearings 60, 62 carried by the ring supports 42 and 50, respectively. Due to the aforedescribed substantial difference in the diameters of the ring supports 42, 50, as shown in FIGS. 1 and 2, the supporting shafts 58 extend inwardly towards the longitudinal centerline of the supporting frame as they extend longitudinally from the ring support 42 towards the ring support 50. Hence, the supporting shafts 58 cooperate with the ring supports 42, to form a structure greatly resembling a truncated cone which has its major base at the ring support 42 and its minor base at the ring support 50.

The supporting shafts 58 each extend through the bearings 60 into one of the cavities 46 and rigidly carry a driven gear 64 in their respective cavity 46. A driving motor 66, preferably fluid or electrically operated, is rigidly carried by the supporting frame 10 within the annular space 38 adjacent each of the supporting shafts 58. The supporting shaft 58 are each independently rotatably driven by their respective adjacent driving motor 66 through a motor shaft 68 rotatable by such driving motor 66 and a driving gear 70 rigidly carried by the motor shaft 68.

The supporting shafts 58 each rigidly support a plurality of serially arranged, elongated toothed cutting rollers 72. Due to the aforedescribed construction of the supporting frame 10, the cutting rollers 72 cooperate with the ring supports 42, 50 of the supporting frame 10 to form a structure greatly resembling a truncated cone which has its major base at the ring support 42 and its minor base at the ring support 50, and each extend inwardly towards the longitudinal centerline of the supporting frame 10 as they extend longitudinally along the outer periphery of the supporting frame 10 towards the leading end 12 of the latter. The cutting rollers 72, furthermore, as shown schematically in FIG. 3, are each sufficiently skewed in the direction of their rotation such that, during their rotation in the direction of the arrow in FIG. 3, the axial component of the force F they exert on the ground exceeds the axial component of the normal force F exerted on the cutting rollers 72 by the ground. Thus, the rotation of the cutting rollers 72 advances the supporting frame 10 forwardly into the tunnel being bored regardless of the hardness of the rock contained in the ground.

A shovel type scoop 74, rigidly connected at its opposing ends to the ring supports 42, 50 and to a plurality of supporting plates 82 rigidly carried by the ring support 50, is interposed between each of the adjacent ones of the supporting shafts 58. The scoops 74 are constructed from a material suitable to provide the supporting frame 10 with a rigid construction between the ring supports 42, 50. The scoops 74, as illustrated in FIGS. 1 and 2, are each constructed in the configuration of an elongated, trapezoidal plate and are bent along their longitudinal edges 76, 78. The scoops 74 are positioned relative to the cutting rollers 72 such that, during their rotation with the supporting frame 10, they collect cut material deposited on the floor of the tunnel being bored. The scoops 74 are constructed of sufficient width such that, as they are rotated upwardly from adjacent the tunnel floor, they discharge their collected material into the opening 44 which is circumferentially enclosed by the ring support 42.

A conical guide member is located within the aligned openings 44, 40, 18 and rigidly connected adjacent its opposing ends to the ring member 16 and the plurality of supporting plates 82 which are rigidly connected to the ring support 42. The guide member 80, as illustrated in FIG. 2, is positioned with its smaller diameter end adjacent the scoops 74 such that material received by the guide member 80 from the scoops 74 is discharged by the former rearwardly of the trailing end 14 of the supporting frame 10. A conveying apparatus, such as the illustrated endless conveying belt '84, is located rearwardly' of the trailing end 14 of the supporting frame 10 and is ositioned to receive material discharged by the guide member 80. The conveyingbeit 84 is suitably arranged to transport the received material to a dump or other suitable place of disposal external to the tunnel being bored by the boring apparatus. In order to facilitate the operation of the boring apparatus, the conveying belt 84 is preferably of the extendible type and connected to the boring apparatus to be automatically extended upon the advancement of such apparatus into the tunnel. Thus, in the embodiment of the invention illustrated in FIGS. 1 through 3, the forward roller 86 supporting the conveying belt 84 is carried by a supporting arm 88 rigidly connected to the annular supoprting member 20.

A ring support 90, having a diameter substantially smaller than that of the ring support 50 and circumferentially enclosing an opening 92, it rigidly carried by the scoops 74 intermediate the ring supports 42, 50 concentric with the latter. A plurality of supporting shafts 94 are dispsoed longitudinally between the ring supports 50, 90 and rotatably journalled adjacent their opposing ends in bearings 96, 98 carried by the ring supports '50, 90, respectively. Due to the substantial difference between the diameters of the ring supports 50, 90, the supporting shafts 94 extend inwardly towards the longitudinal centerline of the supporting frame 10 as they extend longitudinally from adjacent the opening 52 in the ring support 50 towards the ring support 90. Thus, the supporting shafts 94 cooperate with the ring supports 50, 90 to form a structure greatly resembling a truncated cone which has its major base at the ring support 50 and its minor base at the ring support 90.

The end of each of the supporting shafts 94 which is journalled in the bearings 98 rigidly carries a driven gear 100. A driving motor 102, preferably fluid or electricaily operated, is rigidly carried by the scoops 74 .adjacent each of the supporting shafts 94. The supporting shafts 94 are each independently rotatably driven by their respective adjacent driving motor 102 through a motor shaft 104, rigidly carrying a driving gear 106, which is rotatable by the driving motor 102.

The supporting shafts 94 each rigidly support a plurality of serially arranged, elongated toothed cutting rollers 108. Due to the aforedescribed construction of the supporting frame 10, the cutting rollers 108 cooperate with the ring supports 50, 90 to form a structure greatly resembling a truncated cone having its major base at the ring support 50 and its minor base at the ring support 90 and extend inwardly as they extend longitudinally from adjacent the ring support 50. Furthermore, the cutting rollers 108 are each sufliciently skewed in the direction of their rotation such that, during their rotation, the axial component of the force they exert on the ground exceeds the axial component of the normal force exered on the cutting rollers 108 by the ground. Thus, the rotation of the cutting rollers 108 advances the supporting frame 10 forwardly into the tunnel being bored regardless of the hardness of the rock contained in the ground.

A means is provided for limiting the penetration rate of the tunnel boring apparatus to prevent the rotation of the cutting rollers 72, 108 from forwardly advancing the supporting frame 10 at a speed which might be sufliciently high to cause stalling of, and/or damage to, the tunnel boring apparatus. As illustrated in FIGS. 1 and 2, this penetration limiting means comprises a plurality of arcuately arranged, toothless rollers 109 which are positioned such that each one is intermediate adjacent ones of the cutting rollers 54. The toothless rollers 109 are individually mounted for independent free rotation by separate roller mountings 111 and are located within rccesses 113 formed in the leading face 51 of the ring support 50. This disposition of the toothless rollers 109, as

will be understood, locates them a relatively small distance rearwardly of the cutting rollers 54. The roller mountings 111, moreover, are preferably constructed such that this relatively small distance can be adjusted to compensate for wear of the cutting teeth of the cutting rollers 54.

In operation, the aforedescribed tunnel boring apparatus is self-advancing during the rotation of the cutting rollers 72, 108 and, hence, does not require the application of large external torques for effecting its advancement. In addition, the aforedescribed relationship to the cutting rollers 72, 108 enables the boring apparatus to form a larger diameter tunnel than is possible with a conventional conical boring apparatus of similar length.

More specifically, due to the aforedescribed positioning of the cutting rollers 72, 108, the rotation of the cutting rollers 72, 108 by the driving motors 66, 102 advances the supporting frame forwardly into the tunnel being bored. By intermittent adjustment of the torque output of the driving motors 66, 102, this advancement of the tunnel boring apparatus may be maintained at a satisfactory penetration rate regardless of variations in the composition of the ground being bored. Moreover, in the event that the penetration of the tunnel boring apparatus increases to a rate which might cause stalling and/ or damage, the toothless rollers 109 will engage the face of the ground forwardly of the ring support 50 to cause the penetration to be reduced to a safe rate.

During the advancement of the supporting frame 10, the cutting rollers 54 form an annular bore having a cross-sectional width larger than that of the ring support 50. The cutting rollers 72 progressively increase the cross-sectional width of this annular bore until the outer limits of the tunnel are defined. Simultaneously, the cutting rollers 108 reduce the inner core left by the cutting rollers 54, 72 until such inner core is either completely removed or reduced to a diameter small enough to cause it to break of its own accord. The material thus removed by the cutting rollers 54, 72, 108 falls by gravity to the floor of the tunnel where it is collected by the scoops 74 during their rotation with the supporting frame 10. The scoops 74 discharge this collected material to the conical guide member 80 which directs it onto the conveying belt 84. The conveying belt 84 transports the material to a dump or other place of disposal external to the tunnel.

During the aforedescribed operation of the tunnel boring apparatus, the supporting frame 10 is guided by the wheels 26 and the rollers 48 to prevent the tunnel from diverting from the desired direction. In the event that a change is desired in the direction of the tunnel, the wheel tracks 28 are merely banked sufficiently to cause the supporting frame 10 to be guided by the wheels 26 in the proper direction. Then, the succeeding operation of the cutting rollers 72, 108 causes the supporting frame 10 to be pivoted on the rollers 48 to divert the supporting frame 10 in the direction that the tunnel is to be diverted.

In some instances, it may be desirable to apply a degree of external axial thrust or force to the supporting frame 10 to assist it in its forward movement. This application of external axial thrust, for example, can be employed to assist the supporting frame 10 in movement through concentrations of rock of varying consistency. Thus, FIG. 4, wherein parts similar to those previously described with regard to the embodiment of the invention illustrated in FIGS. 1, 2 are designated by the reference character for their similar previously described part followed by the sufiix a, illustrates an alternative embodiment of the invention which includes a device for applying a degree of external axial thrust to the supporting frame 10a.

More specifically, as shown in FIG. 4, a thrust bearing 110 is interposed between the nonrotatable, annular supporting member a and the ring member 16a which forms the trailing end 14a of the rotatable supporting frame 10a. Axial thrust is supplied to the supporting frame 10a by a pair of fluid operated motors 112 which each include a cylinder 114 pivotally connected by a pivot pin 116 to a connecting arm 118 rigidly mounted on the annular supporting member 20a.

An anchor base 126 is located in the tunnel rearwardly of the annular supporting member 20a. The anchor base 126 comprises a central connecting rod 124 pivotally connected to one end of each of a plurality of linkage arms 128 which extend laterally in the tunnel. The opposing ends of the linkage arms 128 are each pivotally connected by a pivot pin 132 to a shoe 130 adapted to engage a wall 30a of the tunnel. The pistons 120 of the fluid operated motors 112 are each pivotally connected by a pivot pin 122 to the central connecting rod 124 of the anchor base 126.

Furthermore, the embodiment of the invention illustrated in FIG. 4 includes an alternative means for limiting the penetration rate of the tunnel boring apparatus. More specifically, as illustrated in FIG. 4, the penetration limiting means comprises a plurality of serially arranged toothless rollers 134 which are rigidly mounted upon rotatable supporting shafts 136 located intermediate adjacent ones of the supporting shafts 58a carrying the cutting rollers 72a. The toothless rollers 134 are arranged such that they are skewed similarly to the cutting rollers 72a and are slightly spaced inwardly from the latter such that they only engage the walls 30a when the penetration rate becomes excessive. Furthermore, the supporting shafts 136 are adjustable relative to the supporting shafts 58a by suitable adjustment means, one of whichis designated generally as 138, to vary the inward spacing of the toothless rollers 72.

In operation, the linkage arms 128 are pivoted relative to the central connecting rod 124 to move the shoes into engagement with the walls 30a of the tunnel to wedge the anchor base 126 in a fixed position. This movement of the linkage arms 128 may be manually accomplished or, alternatively, may be effected by fluid operated motors (not shown) connected between the central connecting rod 124 and the shoes 130. Thereafter, actuation of the fluid operated motors 112 to extend the pistons 120 applies axial thrust to the annular supporting member 20a to urge the supporting frame 10a forwardly in the tunnel. Furthermore, by differential operation of the fluid operated motors 112 the tunnel boring apparatus may be steered to control the direction of the tunnel which it forms. The operation of the penetration limiting means is believed to be obvious from the aforegoing description of such means.

Although I have illustrated and hereinbefore specifically described only two embodiments of my invention, it will be understood that my invention is not limited merely to these illustrated and described embodiments, but rather includes other embodiments and variations employing the concepts and teachings of these illustrated and described embodiments. For example, and not by way of limitation, the cutting rollers 72, 108 could each be mounted upon individual supporting shafts which are independently rotatably driven, providing that the arrangement of the cutting rollers 72, 108 is maintained substantially as hereinbefore described. Moreover, the toothless rollers 109, illustrated in FIGS. 1 and 2, could be mounted on hydraulic rams and held against the ground by a variable force provided by selective supply of hydraulic fluid to the cylinders containing the hydraulic rams.

Having thus described my invention, I claim:

1. In an apparatus for boring a tunnel in the ground, the combination of:

a rotatable supporting frame including a leading end having an opening;

a plurality of toothed cutting rollers carried by said supporting frame for forming a hole forwardly of said leading end;

an outer plurality of toothed cutting rollers rotatably carried by said supporting frame adjacent the outer periphery thereof and cooperating with said supporting frame to form a truncated cone having its minor base adjacent the leading end of said supporting frame; I

an inner plurality of toothed cutting rollers rotatably carried by said supporting frame inwardly by said outer plurality and extending from adjacent the opening in said leading end of said supporting frame;

said inner plurality cooperating with said supporting frame to form a cone having a base adjacent said leading end thereof; and

means connected to said inner and outer pluralities of cutting rollers for rotatably driving the latter;

said inner and outer pluralities of cutting rollers being skewed such that their rotation by said driving means forwardly advances said supporting frame.

2. A tunnel boring apparatus according to claim 1, wherein said toothed cutting rollers for forming a hole forwardly of said leading end are carried by said leading end, and nontoothed rollers are carried by said leading end intermediate said toothed cutting rollers.

3. A tunnel boring apparatus according to claim 1, wherein a plurality of nontoothed rollers are carried by said supporting frame adjacent the outer periphery thereof.

4. A tunnel boring apparatus according to claim 1, wherein means are provided for forwardly urging said supporting frame, said urging means comprising a base adapted to be locked in a fixed position, and a fluid operated motor connected to said supporting frame and to said base operable to urge said supporting frame from said base.

5. A tunnel boring apparatus according to claim 1, wherein scoop means are carried by said supporting frame for collecting material cut by said cutting rollers.

6. In an apparatus for boring a tunnel in the ground, the combination of:

a supporting frame having a leading end and a trailing end and including an opening at said leading end;

a first plurality of toothed cutting rollers rotatably carried by said supporting frame and extending longitudinally along the outer periphery of said supporting frame towards said leading end;

said first plurality of cutting rollers being arranged to extend inwardly as they extend longitudinally towards said leading end of said supporting frame and being skewed in the direction of their rotation;

a second plurality of cutting rollers rotatably carried by said supporting frame inwardly of said first plurality of cutting rollers and extending longitudinally from adjacent the opening at said leading end of said supporting frame;

said second plurality of cutting rollers being arranged to extend inwardly as they extend longitudinally from adjacent the opening in said leading end of said supporting frame and being skewed in the direction of their rotation;

means connected to said first and second pluralities of cutting rollers for rotatably driving said first and second pluralities of cutting rollers; and

cutting means carried by said supporting frame and projecting forwardly of the leading end of said supporting frame for cutting forwardly of the leading end of said supporting frame.

7. A tunnel boring apparatus according to claim 6, further comprising roller means carried by said supporting frame for limiting the penetration rate of the tunnel boring apparatus.

8. A tunnel boring apparatus according to claim 7, further comprising said roller means including at least one nontoothed roller.

9. A tunnel boring apparatus according to claim 6, further comprising said first plurality of cutting rollers cooperating with said supporting frame to form a truncated cone having its minor base adjacent the leading end of said supporting frame, and said second plurality of cutting rollers cooperating with said supporting frame to form a cone having a base adjacent said leading end of said supporting frame.

10. A tunnel boring apparatus according to claim 9, further comprising a scoop carried by said supporting frame for rotation therewith whereby said scoop, during the rotation of said supporting frame, collects material cut by said cutting rollers, and chute means carried by said supporting frame and arranged to receive material from said scoop and to discharge such material rearwardly of said supporting frame.

'11. A tunnel boring apparatus according to claim 6, wherein a support is disposed adjacent said trailing end of said supporting frame, and said trailing end of said supporting frame is rotatably connected to said support.

:12. A tunnel boring apparatus according to claim 11, wherein a plurality of nontoothed rollers are carried by said supporting frame adjacent the outer periphery thereof.

13. A tunnel boring apparatus according to claim 11, wherein a scoop is connected to said supporting frame for rotation with said supporting frame such that said scoop, during the rotation of said supporting frame, collects material cut by said cutting rollers.

14. A tunnel boring apparatus according to claim 11, wherein said cutting means for cutting forwardly of said leading end comprises a plurality of toothed cutting rollers carried by said leading end.

15. A tunnel boring apparatus according to claim 14, wherein a plurality of nontoothd rollers are carried by said leading end adjacent said toothed cutting rollers carried by said leading end.

16. A tunnel boring apparatus according to claim 14, wherein means are provided for forwardly urging said supporting frame, said urging means comprising a base adapted to be locked in a -fixed position, and a fluid operated motor connected to said support and to said base for urging said support and said supporting frame from said base.

'17. A tunnel boring apparatus according to claim 16, wherein said base of said urging means comprises a plurality of shoe members adapted to engage the walls of a tunnel and linkage means for maintaining said shoe members in engagement with the walls of a tunnel, and said fluid operated motor is connected to said linkage means.

References Cited UNITED STATES PATENTS 1,453,620 5/1923 Carlson l332 X 1,659,942 2/1928 Carlson 299-58 2,024,730 12/1935 Hammer -333 2,029,770 2/1936 Grant l75346 2,549,420 4/1951 Camp l75333' 2,769,614 11/1956 Zent l7594 FOREIGN PATENTS 852,537 10/ 1960 Great Britain. 135,061 6/1960 U.'S.S.R.

ERNEST R. PURSER, Primary Examiner.

US. Cl. X.R. l75-333, 94, 96; 29956, 86 

